Does anyone have experience with this? I have a prop pistol and a gunbelt/holster for it. I'd obviously pack it in my checked luggage, but has anyone had any issues? Is it something you have to declare so you don't freak out the luggage check people...?

When you're packing, lay all the contents of your checked bag out (also helps with making sure you've got everything).

Take a picture of it, and put it in the middle of a letter that says something like:

" Hello baggage inspector,

I am a nerd going to a big Science Fiction Conviction. I dress up in costumes and pictured below is an overlay of the contents of this bag. None of these are real weapons and all props are harmless. Thank you for your time, and my apologies for any inconvenience. "

Then place the open letter on top of you stuff. When they open it, they'll see the letter, and 9/10 times they open it, read the letter, place the letter back down, set a TSA letter on it, and send it along without digging through everything.

Never use any word to give them pause. Weapon, gun, sword, anything like that. Stick with toy, prop, and costume piece. I almost had yard sticks wrapped in tape confiscated because I said "part of a costume weapon".

Seconding this. I have not done it myself but for some really costume heavy cosplay friends of mine this has always been the method for long distance conventions. It will save you any heartache especially if you get a TSA agent that is very overzealous.

Instead use that extra space to pack some repair supplies incase of minor damage during shipment.

The TSA has a process for checking real steel weapons and other items, so take ques from that. The idea that was posted on here to put a note on your baggage is great.

Traveling to different states you might need to put orange paint on your fake weapon. You have to have a permanent fixed bright orange on your weapon tip. This is for only a few gun strict states and such (Georgia is not one of them). Also call your local airport you are leaving from and ask them what to do. There here to help you.